Forging die heating apparatuses and methods for use

ABSTRACT

A forging die heating or preheating apparatus comprises a burner head comprising a plurality of flame ports. The burner head is oriented to compliment an orientation of at least a region of a forging surface of a forging die and is configured to receive and combust a supply of an oxidizing gas and a supply of a fuel and produce flames at the flame ports. The plurality of flame ports are configured to impinge the flames onto the forging surface of the forging die to substantially uniformly heat at least the region of the forging surface of the forging die.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 120 as division ofU.S. patent application Ser. No. 13/744,566, filed Jan. 18, 2013, whichin turn claims priority under 35 U.S.C. § 120 as a continuation of U.S.patent application Ser. No. 12/480,246, filed on Jun. 8, 2009, nowissued as U.S. Pat. No. 8,381,563. The contents of each such case arehereby incorporated by reference in their entireties.

BACKGROUND OF THE TECHNOLOGY Field of the Technology

The present disclosure relates to equipment and techniques for forgingdie heating. The present disclosure more specifically relates toequipment and techniques for heating a forging surface of a forging die.

Description of the Background of the Technology

A work piece, such as an ingot or a billet, for example, can be forgedinto a particular configuration or shape using a forging die. Forgingdies can comprise open-faced forging dies, closed-faced or “impression”forging dies, or other suitable forging dies. Most open-faced forgingdies can comprise a first or a top portion and a second or a bottomportion. In general, the bottom portion can act as an “anvil” or astationary portion, while the top portion can act as the “hammer” or amovable portion as it moves toward and away from the bottom portion. Inother open-faced forging dies, both the top and the bottom portions canmove toward each other or, in still other configurations, the bottomportion can move toward a stationary top portion, for example. Themovement of the top or bottom portions of the forging die can beaccomplished through the use of pneumatic actuators or hydraulicactuators, for example. In any event, the top and bottom portions of theforging die can be disposed in an open position, where they are spaced asuitable distance from each other, and in a closed position, where theycontact or nearly contact each other.

During the forging process, a portion of the work piece can bepositioned between the top portion and the bottom portion of the forgingdie and forged by force applied by the top portion and/or the bottomportion. Applying such force to the work piece can change the structuralproperties and/or the crystalline structure of the work piece, such asthrough work hardening, thereby possibly developing weak spots in thework piece. Work hardening, for example, may be inhibited if the workpiece is heated to a suitable temperature prior to or during the forgingprocess. Heating of the work piece can make the work piece moremalleable such that it can be forged using less force applied by the topand/or the bottom portions of the forging die. Depending on thecomposition of the work piece, the work piece can be heated to atemperature in the range of 1800-2100 degrees Fahrenheit, for example,prior to being forged, to facilitate forging of the work piece. As canbe seen, various benefits may be achieved by heating the work pieceprior to and/or during forging.

In addition to the heating of the work piece prior to and/or duringforging, in some instances, the top and/or bottom portions of theforging die can also be heated to reduce or minimize any temperaturedifferential between the heated work piece and the top and bottomportions of the forging die. Through such heating, surface cracking ofthe work piece during forging can be reduced relative to forging using aforging die at ambient temperature (20-25 degrees Celsius). For example,if a region of a work piece heated to a temperature of 1800-2100 degreesFahrenheit contacts a forging die at ambient temperature, thesignificant temperature differential reduces the temperature of the workpiece region and adjacent regions. The significant temperaturedifferential can create mechanically weak regions within the work piecethat may make the work piece unsuitable for its intended application.Further, in some instances, the significant temperature differentialbetween forging die and work piece can lead to inclusions in the workpiece caused by non-uniform cooling of the work piece during and afterforging if the region of the work piece contacted by the ambienttemperature forging die cools faster than the rest of the heated workpiece.

In an attempt to minimize these negative consequences, referring to FIG.1, certain forging techniques employ a single torch 2 aimed at a forgingdie 4 to preheat much or all of the forging die 4 prior to forging awork piece (not illustrated). This single torch 2 can be a natural gasor a propane air-aspirated torch, for example. Because a single torch 2is used, this forging die preheating technique can take several hours orlonger and may only heat the forging die 4 to a temperature in the rangeof 600-800 degrees Fahrenheit, for example. In most instances, theforging die 4 is heated with the top portion 6 and the bottom portion 8of the forging die 4 in a closed, or substantially closed, position. Assuch, the single torch 2 can be moved vertically about a side surface 9of the top and bottom portions 6 and 8 of the forging die 4 in thedirections indicated by arrow “A” and arrow “B”, for example, to heatthe forging die 4. Also, the single torch 2 can be moved horizontallyabout the side surface 9 of the top and bottom portions 6 and 8 of theforging die 4 in the directions indicated by arrow “C” and arrow “D”, toheat the forging die 4. In other embodiments, the single torch 2 can bemoved both horizontally and vertically about the side surface 9. Ofcourse, the single torch 2 can also be moved about the side surface 9 ofthe forging die 4 in any other suitable direction or can remainstationary.

Such preheating of the forging die, although helpful in the forgingprocess, can lead to non-uniform heating of the forging die 4 or aforging surface 5 of the forging die 4, again possibly resulting ininclusions or weak spots in the work piece where the forging die 4contacts and cools the work piece. Another issue with theabove-described preheating practice is that, even though the forging die4 can be heated to about 600-800 degrees Fahrenheit, there can still bea substantial temperature differential between the work piece, which maybe at forging temperatures of about 1800-2100 degrees Fahrenheit, andthe forging die 4. The existence of a significant temperaturedifferential between the work piece and the forging surface 5 cansometimes lead to surface cracking of crack-sensitive alloy work pieces,such as Alloy 720, Rene '88, and Waspaloy, for example. Further, thenon-uniform cooling produced by temperature differentials can, in someinstances, cause inclusions or weak spots within work pieces of thesealloys.

Given the drawbacks associated with conventional forging die pre-heatingtechniques, it would be advantageous to develop alternative pre-heatingtechniques.

SUMMARY OF THE TECHNOLOGY

According to one non-limiting aspect of the present disclosure, anembodiment of a forging die heating apparatus comprises a burner headcomprising a plurality of flame ports. The burner head is oriented tocompliment an orientation of at least a region of a forging surface of aforging die. The burner head is configured to receive and combust asupply of an oxidizing gas and a supply of a fuel and produce flames atthe flame ports. The plurality of flame ports are configured to impingethe flames onto at least a region of the forging surface of the forgingdie to substantially uniformly heat at least a region of the forgingsurface of the forging die.

According to another non-limiting aspect of the present disclosure, anembodiment of a forging die heating apparatus comprises a burner headcomprising a plurality of flame ports. The burner head is configured tobe at least partially conformed to an orientation of a region of aforging surface of a forging die. The burner head is configured toreceive and combust a supply of an oxidizing gas and a supply of a fueland produce flames at the flame ports. The plurality of flame ports areconfigured to impinge the flames onto and substantially uniformly heatthe region of the forging surface of the forging die.

According to yet another non-limiting aspect of the present disclosure,an embodiment of an open-faced forging die heating apparatus comprises aburner comprising a manifold configured to receive a supply of anoxidizing gas and a supply of fuel and a burner head. The burner headcomprises a first portion comprising a first set of flame portscomprising at least two flame ports. The first set of flame ports are influid communication with the manifold such that the first set of flameports are configured to impinge at least two flames onto a first regionof a forging surface of a forging die. The burner head further comprisesa second portion comprising a second set of flame ports comprising atleast two flame ports. The second set of flame ports are in fluidcommunication with the manifold such that the second set of flame portsare configured to impinge at least two flames onto a second region ofthe forging surface of the forging die, wherein an orientation of theburner head conforms to an orientation of at least the first region ofthe forging surface of the forging die.

According to still another non-limiting aspect of the presentdisclosure, an embodiment of a forging die preheating apparatuscomprises a burner head comprising a first flame port, a second flameport, and a third flame port. The second flame port is substantially thesame distance from the first flame port and the third flame port. Theburner head is configured to receive and combust a supply of anoxidizing gas and a supply of fuel to produce a flame at each of thefirst flame port, the second flame port, and the third flame port. Eachof the first flame port, the second flame port, and the third flame portare configured to impinge the flames onto at least a region of a forgingsurface of a forging die and preheat the region of the forging surfaceprior to forging a work piece with the forging die.

According to still another non-limiting aspect of the presentdisclosure, an embodiment of a method of heating a forging die comprisespositioning a burner head comprising at least two flame ports inproximity to a region of a forging surface of the forging die. Themethod further comprises supplying an oxy-fuel to the at least two flameports and combusting the oxy-fuel at the at least two flame ports toproduce an oxy-fuel flame at each of the at least two flame ports. Themethod further comprises impinging at least two of the oxy-fuel flamesonto the region of the forging surface of the forging die andsubstantially uniformly heating the region of the forging surface of theforging die.

According to still another non-limiting aspect of the presentdisclosure, an embodiment of a method of preheating an open-facedforging die comprises positioning a burner head comprising at least twoflame ports in a location at least partially intermediate a firstforging surface of the forging die and a second forging surface of theforging die. The burner head is oriented to at least partially conformto an orientation of at least one of the first forging surface and thesecond forging surface. The method further comprises supplying a fuel tothe at least two flame ports, combusting the fuel to produce a flame ateach of the at least two flame ports, and impinging at least two of theflames onto at least one of the first forging surface and the secondforging surface.

According to yet another non-limiting aspect of the present disclosure,an embodiment of a forging die drift hard-stop system for a forging dieapparatus including a top forging portion attached to a cross head and abottom forging portion is provided. The forging die drift hard-stopsystem comprises an arm comprising a first end and a second end. Thesecond end of the arm is pivotably attached to a portion of the forgingdie apparatus and a spacer is attached to the first end of the arm. Thearm is movable between a first position, where the spacer is free fromengagement with a portion of the forging die apparatus and a portion ofthe cross head, and a second position, where the spacer is engaged withthe portion of the forging die apparatus and the portion of the crosshead to inhibit movement of the top forging portion toward the bottomforging portion.

According to still another non-limiting aspect of the presentdisclosure, an embodiment of a forging die heating apparatus isprovided. The forging die heating apparatus comprises an arm and aburner head movably attached to the arm. The burner head is configuredto be moved between a first position relative to the arm and a secondposition relative to the arm. The forging die heating apparatus furthercomprises a plurality of burner nozzles positioned on the burner headand at least one assembly in fluid communication with the plurality ofburner nozzles. The at least one assembly comprises an air aspiratorconfigured to allow air to enter the burner head and an orificeconfigured to allow a combustible fuel to flow therethrough.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the apparatus and methods described hereinmay be better understood by reference to the accompanying drawings inwhich:

FIG. 1 is a schematic illustration of a conventional forging die heatingprocess;

FIG. 2 is a simplified depiction of certain components of onenon-limiting embodiment of a forging die heating apparatus according tothe present disclosure;

FIG. 3 is a top view of certain components of the forging die heatingapparatus illustrated in FIG. 2;

FIG. 4 is a perspective view of certain components of the forging dieheating apparatus illustrated in FIG. 3;

FIG. 5A is a cross-section view taken along line 5-5 and in thedirection of the arrows in FIG. 3, illustrating certain components ofthe forging die heating apparatus of FIG. 2, according to one embodimentof the present disclosure;

FIG. 5B is a cross-section view taken along line 5-5 and in thedirection of the arrows in FIG. 3, illustrating certain components ofthe forging die heating apparatus of FIG. 2, according to one embodimentof the present disclosure;

FIG. 5C is a cross-section view taken along line 5-5 and in thedirection of the arrows in FIG. 3, illustrating certain components ofthe forging die heating apparatus of FIG. 2, according to one embodimentof the present disclosure;

FIGS. 6-11 are schematic illustrations of certain components of variousnon-limiting embodiments of forging die heating apparatuses according tothe present disclosure;

FIG. 12 is a schematic illustration of certain components of anothernon-limiting embodiment of a forging die heating apparatus according tothe present disclosure;

FIG. 13 is a schematic illustration of yet another non-limitingembodiment of a forging die heating apparatus according to the presentdisclosure, comprising an actuator;

FIG. 14 is a schematic illustration of still another non-limitingembodiment of a forging die heating apparatus according to the presentdisclosure, comprising an actuator;

FIG. 15 is a schematic illustration of a portion of a forging diecomprising a plurality of sensors for monitoring the temperature ofvarious regions of the forging die according to one non-limitingembodiment of the present disclosure;

FIG. 16 is a flow chart of a closed loop on/off flame impingement systemaccording to one non-limiting embodiment of the present disclosure;

FIG. 17 is a schematic illustration of a portion of a forging diecomprising a plurality of sensors for monitoring the temperature ofvarious regions of the forging die and/or the forging die surfaceaccording to one non-limiting embodiment of the present disclosure;

FIG. 18 is a flow chart of a closed loop on/off flame impingement systemaccording to one non-limiting embodiment of the present disclosure;

FIG. 19 is a schematic illustration of a forging die temperature sensingsystem according to one non-limiting embodiment of the presentdisclosure;

FIG. 20 is a perspective view of a forging die apparatus with a forgingdie drift hard-stop system according to one non-limiting embodiment ofthe present disclosure; and

FIG. 21 is a perspective view of a forging die heating apparatusaccording to one non-limiting embodiment of the present disclosure.

The reader will appreciate the foregoing details, as well as others,upon considering the following detailed description of certainnon-limiting embodiments of apparatuses and methods according to thepresent disclosure. The reader also may comprehend certain of suchadditional details upon carrying out or using the apparatuses andmethods described herein.

DETAILED DESCRIPTION OF CERTAIN NON-LIMITING EMBODIMENTS

In the present description of non-limiting embodiments, other than inthe operating examples or where otherwise indicated, all numbersexpressing quantities or characteristics of elements, ingredients andproducts, processing conditions, and the like are to be understood asbeing modified in all instances by the term “about”. Accordingly, unlessindicated to the contrary, any numerical parameters set forth in thefollowing description are approximations that may vary depending uponthe desired properties one seeks to obtain in the apparatuses andmethods according to the present disclosure. At the very least, and notas an attempt to limit the application of the doctrine of equivalents tothe scope of the claims, each numerical parameter should at least beconstrued in light of the number of reported significant digits and byapplying ordinary rounding techniques.

The present disclosure, in part, is directed to improved designs forforging die heating apparatuses configured to heat a forging die or allor a region of a forging surface of a forging die. In one non-limitingembodiment, referring to FIG. 2, a forging die 10 can comprise a topportion 12 and a bottom portion 14. The top portion 12 of the forgingdie 10 can be movable with respect to the bottom portion 14 of theforging die 10 or vice versa, for example. In one non-limitingembodiment, this movement can be accomplished through the use ofpneumatic and/or hydraulic actuators. In other non-limiting embodiments,the top portion 12 and the bottom portion 14 can both be movablerelative to each other. In certain non-limiting embodiments, the topportion 12 can act as the “hammer” and the bottom portion 14 can act asthe “anvil” such that at least a portion of a work piece (notillustrated) can be positioned intermediate the top portion 12 and thebottom portion 14 during forging of the work piece. The forging can takeplace owing to significant force applied to at least a portion of thework piece by the top portion 12 and/or the bottom portion 14 of theforging die 10. The top portion 12 can comprise a first forging surface16 and the bottom portion 14 can comprise a second forging surface 18.The first and second forging surfaces 16 and 18 are generally broughtinto contact with regions of the work piece during forging to forge thework piece into a desired shape and/or to have a desired dimension. Invarious non-limiting embodiments, the forging die 10 can be anopen-faced forging die, for example. In other non-limiting embodiments,the forging die can be a closed or “impression” forging die, or can haveany other suitable forging die design.

Prior to forging, it may be desirable to heat or preheat (hereinafterthe terms “preheat” or “preheating” will also encompass the terms “heat”or “heating”, and vice versa) all or a region of the first forgingsurface 16 and/or the second forging surface 18 of the forging die 10.Such heating can reduce a temperature differential between a heated workpiece and the first and/or the second forging surfaces 16 and 18.Convention preheating techniques using a single torch, however, canrequire hours to heat a forging die given that the techniques involvepreheating only a small area of a side surface of the forging die at anyone time. Using such convention preheating techniques can also result innon-uniform heating of the first and second forging surfaces 16 and 18.As a result, when the forging surfaces 16 and 18 contact the work piece,a first region of the forging surfaces 16 and 18 may be a firsttemperature and a second region of the forging surfaces 16 and 18 may bea substantially different second temperature, thereby possibly resultingin surface cracking and/or non-uniform cooling of the work piece, forexample. Further, such conventional preheating techniques may notpreheat the first and/or second forging surfaces 16 and 18 to atemperature substantially the same as the heated work piece, therebyallowing a significant temperature differential to exist between thework piece and/or the first and second forging surfaces 16 and 18 of theforging die 10. If a significant temperature differential exists, theportion of the work piece contacting the forging surfaces 16 and 18 maybe cooled too quickly, which can lead to surface cracking and/orinclusions within the work piece, for example.

To provide uniform, or substantially uniform, preheating of at least aregion of the first and/or the second forging surfaces 16 and 18, animproved forging die heating apparatus 20 is provided. Hereinafter theterms “forging surface” or “forging surfaces” may comprise regions ofboth the top and bottom portions of the various forging dies. As shownin FIG. 2, the forging die heating apparatus 20 can be configured to bepositioned at least partially intermediate the top and bottom portions12 and 14 of the forging die 10. As such, the forging die heatingapparatus 20 can be configured to be positioned at least partiallyintermediate and opposing the first forging surface 16 and the secondforging surface 18 of the forging die 10. In one non-limitingembodiment, the forging die heating apparatus 20 can be positionedproximate to at least one of the first forging surface 16 and the secondforging surface 18 such that it can impinge two or more flames onto atleast a region of at least one of the forging surfaces 16 and 18 of theforging die 10 to preheat the forging surfaces 16 and/or 18 prior toforging a work piece with the forging die 10.

In one non-limiting embodiment, aspects of which are schematicallyillustrated in FIGS. 2-5C, the forging die heating apparatus 20 cancomprise a burner or a burner head 22 configured to be in fluidcommunication with a supply of an oxidizing gas and a supply of a fuel.The burner head 22 can be comprised of brass or any other suitablethermally conductive metal or material, such as copper, for example,that can withstand the high temperatures generated by the burner head22. In various non-limiting embodiments, the burner head 22 can compriseany suitable shape, orientation, and/or dimensions configured to conformthe burner head 22 to an orientation of a forging surface of a forgingdie or region of the forging surface. As used herein, “conform” can meanto configure to an orientation of a forging surface, or a region of aforging surface, of a forging die, to place in proximity to, or closeproximity to, a forging surface, or a region of a forging surface, of aforging die, and/or to orient to compliment a forging surface, or aregion of a forging surface, of a forging die.

In one non-limiting embodiment, the burner head 22 can be in fluidcommunication with one or more mixing devices or torches 24 configuredto receive the supply of the oxidizing gas and the supply of the fueland provide a mixed supply of the oxidizing gas and the fuel to theburner head 22 via conduit 31. Although oxidizing gas and fuel supplylines are not illustrated in FIG. 2, it will be understood that thevarious mixing torches discussed herein are in fluid communication witha supply of an oxidizing gas and a supply of a fuel. In one non-limitingembodiment, the mixing torch 24, although illustrated as having arectangular shape herein, can comprise any suitable configuration and/orshape. Additionally, although a mixing torch is not illustrated anddescribed with respect to each non-limiting embodiment of the forgingdie heating apparatuses described herein, it will be apparent from thedisclosure that a mixing torch can be used with each non-limitingembodiment of the present disclosure or other various embodimentsrequiring the mixing of a fuel and an oxidizing gas to provide a mixedsupply of the fuel and the oxidizing gas to a burner head included inthe forging die heating apparatuses.

In one non-limiting embodiment, referring to FIG. 2, the burner head 22can be cooled using a liquid, such as water, for example, or otherliquid, vapor, and/or gas having sufficient heat transfer or absorptioncapabilities. This cooling may be provided to prevent or at leastinhibit melting of the burner head 22, or portions of the burner head22, during heating of the forging surfaces 16 and 18 of the forging die10. The liquid can be supplied to the burner head 22 through line 25 andcan exit the burner head 22 through another line 25′ or through aportion of the line 25, for example. In such a non-limiting embodiment,the liquid can be passed through one or more passages or channels in theburner head 22 to cool the burner head 22 or portions thereof. In onenon-limiting embodiment, lines 25 and 25′ can be rigid such that theycan be used to move the burner head 22 into and out of a position atleast partially intermediate the top portion 12 and the bottom portion14 of the forging die 10.

In one non-limiting embodiment, the burner head 22 can be comprised of ahighly heat conductive material, such as brass or copper, for example.The burner head 22 can also comprise one or more mixing chambers ormanifolds (referred to collectively as “manifold”) configured to receivea mixed supply of a fuel, such as natural gas, methane, and/or propane,for example, and an oxidizing gas, such as air or pure oxygen, forexample. The one or more manifolds can be in fluid communication withvarious flame ports 26 of the burner head 22 such that the mixed supplycan be provided to the flame ports 26 and combusted at the flame ports26. At least one passage or channel, configured to receive a coolingliquid, vapor, and/or gas can at least partially surround, be positionedadjacent to, and/or be positioned proximate to, the one or moremanifolds. Of course, the hottest portion of the burner head 22 isusually the portion of the burner head 22 comprising the flame ports 26.One object of the cooling system is to extract any excessive heat in thewalls of the one or more manifolds and/or the walls of the flame ports26 to prevent, inhibit, or at least minimize the chance of, internalexplosions and/or combustion within the one or more manifolds of theburner head 22 owing to the heat within the burner head 22. In somecircumstances, these internal explosions and/or combustion can cause theburner head 22 to operate in inefficiently. Thus, by providing distinctmanifolds and passages or channels for the fuel and oxidizing gasmixture and the liquid, respectively, along with the highly heatconductive materials of the burner head 22, heat can easily bedissipated from the walls of the one or more manifolds and/or the wallsof the flame ports 26.

In non-limiting exemplary embodiments, the above-referenced coolingsystem is illustrated in FIGS. 5A-5C. FIGS. 5A-5C are exemplarycross-sectional views of the burner head 22 taken along line 5-5 of FIG.3. Referring to FIG. 5A, the burner head 22′ can comprise one or moremanifolds 21′ in fluid communication with various flame ports 26′ suchthat the mixed supply of the fuel and the oxidizing gas can be suppliedto the flame ports 26′ for combustion. The burner head 22′ can alsocomprise at least one passage 23′ or channel positioned to cool thewalls 31′ of the one or more manifolds 21′ and/or the walls of the flameports 26′ when a liquid, such as water, for example, is flowed throughthe passage 23′. In one non-limiting embodiment, the one or moremanifolds 21′ can be separated by walls formed of the same highlyconductive material as the burner head 22′. As such, the cooling systemcan allow at least a portion of the heat within the walls 31 and/or thewalls of the flame ports 26′ to be transferred to the water or otherliquid, vapor, and/or gas within the passage 23′ and removed from theburner head 22′ to maintain the burner head 22′ at a cool temperaturerelative to the temperature of flames 29′. Referring now to FIG. 5B, aburner head 22″ can comprise one or more manifolds 21″ in fluidcommunication with various flame ports 26″. The burner head 22″ can alsocomprise a plurality of passages 23″ or channels at least partiallysurrounding portions of the walls 31″ of the one or more manifolds 21″and/or walls of the flame ports 26″. As such, at least a portion of theheat within the walls 31″ and/or the walls of the flame ports 26 can betransferred to the liquid and removed from the burner head 22″ by theflowing liquid to maintain the burner head 22″ at a cool temperaturerelative to the temperature of flames 29″. Referring to FIG. 5C, burnerhead 22′″ can comprise a plurality of manifolds 21′″ each in fluidcommunication with at least one flame port 26′″. The burner head 22′″can also comprise a plurality of passages 23′″ or channels at leastpartially surrounding portions of the walls 31′″ of the manifold 21′″and/or walls of the flame ports 26′″. In one non-limiting embodiment,the manifolds 21′″ and the passages 23′″ can be positioned in analternating pattern across the burner head 22′″ such that the walls 31′″of the manifolds 21′″ and/or the walls of the flame ports 26′″ can be atleast somewhat uniformly cooled by the water or other liquid, vapor,and/or gas being passed through the passages 23′″. As such, at least aportion of the heat within the walls 31′″ and/or the walls of the flameports 26′″ can be transferred to the liquid and removed from the burnerhead 22′″, as the liquid flows through the burner head 22.

Although not illustrated or described with respect to each non-limitingembodiment of the present disclosure, it will be understood that aliquid cooling system, or other cooling system, can be used with eachnon-limiting embodiment of the present disclosure.

Further to the above, referring to FIGS. 2-5C, the burner head 22 cancomprise at least two, or a plurality of (i.e., three or more), flameports 26 on at least one surface 28 thereof. The burner head 22 can beconfigured to receive and combust the mixed supply of the oxidizing gasand the fuel from the mixing torch 24 to produce flames 29 at the flameports 26 (see e.g., FIG. 2). In one non-limiting embodiment, the flameports 26, and the other flame ports discussed herein, can be uniformly,or substantially uniformly, spaced with respect to each other about theat least one surface 28 so as to better uniformly convey heat. If largerflame ports 26 are used, less flame ports 26 may be required owing tothe larger flames produced, when compared to the use of smaller flameports 26, which may require more flame ports 26. In any event, theflames 29 can overlap each other as they extend from the various flameports to substantially uniformly heat various forging surfaces.

In one exemplary non-limiting embodiment, the flame ports 26 can have a0.030 inch diameter or a diameter in the range of 0.015 inches to 0.1inches, for example. Smaller flame ports can be spaced one half of oneinch from other flame ports on the surface 28 of burner head 22, forexample, to provide uniform, or substantially uniform, preheating of theforging surface(s) 16 and/or 18 of the forging die 10. Larger flameports can be spaced one inch from each other, for example, to provideuniform, or substantially uniform, preheating of the forging surface(s)16 and/or 18 of the forging die 10. Of course, other suitable flame portspacing is within the scope of the disclosure. In one non-limitingembodiment, the flame ports 26 can comprise any suitable shape such ascircular, ovate, and/or conical, for example. In other non-limitingembodiments, as will be apparent to those of ordinary skill in the artupon consideration of the present disclosure, any other suitable flameport diameters, shapes, configurations, and/or flame port spacing can beused. In one non-limiting embodiment, the substantially uniformly spacedflame ports can each produce a substantially uniform flame to betterprovide for substantially uniform preheating of one or more forgingsurface, for example. In one non-limiting embodiment, the various flameports 26 can be cleaned after one or more uses, such that none of theflame ports 26 remain or become blocked by combustion residue, debris,or other materials produced by the forging die preheating process. Inone non-limiting embodiment, a drill bit, such as a number 69 drill bit,for example, may be used to clean the flame ports 26. In othernon-limiting embodiments, an automated computer numerical controlled(“CNC”) machine can be programmed to clean the flame ports 26, forexample.

With reference to FIGS. 2 and 5A-5C, in one non-limiting embodiment, theburner head 22 can comprise a hollow manifold 21′, 21″, or 21′″(hereafter “21”) configured to mix the supply of the oxidizing gas withthe supply of the fuel and/or receive a mixed supply of the oxidizinggas and the fuel from one or more mixing torches 24. The manifold 21 canbe in fluid communication with the plurality of flame ports 26 such thatit can deliver the mixed supply of the oxidizing gas and the fuel to theflame ports 26 for combustion at the flame ports 26. The passages 23′,23″, and/or 23′″, described above can extend through and/or surroundportions of the manifold 21, for example, for cooling of the burner head22 through heat transfer to the liquid, vapor, and/or gas flowingthrough the passages 23′, 23″ and/or 23′″. Although the manifold 21 isillustrated in fluid communication with the flame ports 26 on onesurface 28 of the burner head 22, it will be apparent from thedisclosure that the manifold can be in fluid communication with flameports on each of two opposed surfaces of the burner head 22, forexample. Further, while the manifold 21 is not illustrated and describedwith respect to each non-limiting embodiment described in the presentdisclosure, those of ordinary skill in the art will recognize that amanifold can be supplied in each burner head described herein. In onenon-limiting embodiment, the burner head 22 can be configured to receiveand combust the mixed supply of the oxidizing gas and the fuel from themanifold 21 to produce the flames 29 at the flame ports 26. The flames29 can be used to preheat at least a region of at least the firstforging surface 16 and/or the second forging surface 18 of the forgingdie 10.

In one non-limiting embodiment, referring to FIG. 6, a first set of atleast two flame ports 126 can be provided on a first side or portion 132of a forging die heating apparatus 120, and a second set of at least twoflame ports 126′ can be provided on a second side or portion 134 of theforging die heating apparatus 120. By providing these two sets of atleast two flame ports 126 and 126′, a first forging surface 116 of a topportion 112 of a forging die 100 and a second forging surface 118 of abottom portion 114 of the forging die 110 can be simultaneously heatedby the forging die heating apparatus 120 when the forging die heatingapparatus 120 is at least partially positioned intermediate the topportion 112 and the bottom portion 114 of the forging die 110. Theburner head 122 and the first and second sets of at least two flameports 126 and 126′ can be in fluid communication with a mixing torch124, via conduit 131, and can be configured to provide a mixed supplycomprising an oxidizing gas and a fuel to the flame ports 126 and 126′and/or to a manifold in fluid communication with the flame ports 126 and126′. In such an embodiment, the burner head 122 can combust the mixedsupply to produce flames 129 and 129′ at the first and second sets of atleast two flame ports 126 and 126′, respectively. In variousnon-limiting embodiments, the forging die heating apparatus 120 can beshaped to conform to at least one of the first forging surface 116 andthe second forging surface 118 of the forging die 110 to enable theforging die heating apparatus 120 to uniformly, or substantiallyuniformly, preheat at least a portion of the first and/or second forgingsurfaces 116 and 118 of the forging die 110.

In various non-limiting embodiments, and still referring to FIG. 6, thefirst and second forging surfaces 116 and 118 can comprise arcuateportions 121 and 121′ joining side walls of 117 and 117′ and the firstand second forging surfaces 116 and 118 of the forging die 110. Touniformly heat these arcuate portions 121 and 121′, the burner head 122can comprise arcuate sections 123 and 123′ proximate to ends of theburner head 122, for example, which arcuate sections 123 and 123′ canconform to a configuration of the arcuate portions 121 and 121′ of theforging surfaces 116 and 118. A burner head 122 provided with thesearcuate sections 123 and 123′, can more uniformly, or substantiallyuniformly, heat and conform to both of the arcuate portions 121 and 121′of the first and second forging surfaces 116 and 118, thereby betterpreventing “cold” spots on the first and second forging surfaces 116 and118 and/or non-uniform preheating of the forging surfaces 116 and 118.While not specifically described in connection with other non-limitingembodiments discussed in the present disclosure, it will be apparentthat the various burner heads can comprise arcuate sections, V-shapedsections, U-shaped sections, convex sections, concave sections, and/orother suitably shaped sections configured to conform to regions of firstand/or second forging surfaces of various forging dies, so as to betterpromote substantially uniform preheating of the forging surfaces orregions of the forging surfaces. In one non-limiting embodiment, line125 can be used to flow a liquid into the burner head 122 to cool theburner head 122 and/or can be used to move the burner head 122 into anout of a position intermediate the first and second forging surfaces 116and 118 of the forging die 110.

Referring to FIG. 7, a forging die heating apparatus 220 for a forgingdie 210 can comprise a burner head 222 comprising a first portion 232and a second portion 234. The first portion 232 can be separate from thesecond portion 234. The first portion 232 can comprise a first set of atleast two flame ports 226 in fluid communication with a mixed supply ofan oxidizing gas and a fuel provided by a mixing torch 224 and/or amanifold (not illustrated). The second portion 234 can likewise comprisea second set of at least two flame ports 226′ in fluid communicationwith a mixed supply of an oxidizing gas and a fuel provided by a mixingtorch 224′ and/or a manifold (not illustrated). The mixing torch 224 canbe in fluid communication with the first portion 232 of the burner head222 via conduit 231 and, similarly, the mixing torch 224′ can be influid communication with the second portion 234 of the burner head 222via conduit 231′.

In one non-limiting embodiment, the first portion 232 of the burner head222 can have a shape conforming to at least a region of a first forgingsurface 216 of the forging die 210, and the second portion 234 can havea shape conforming to at least a region of a second forging surface 218of the forging die 210. The first portion 232 can be configured toreceive and combust the mixed supply of the oxidizing gas and the fuelto produce a first set of at least two flames 229 at the first set of atleast two flame ports 226. The first set of at least two flames 229 canbe impinged on the first forging surface 216 of the forging die 210through the first set of at least two flame ports 226 to heat the firstforging surface 216. Likewise, the second portion 234 can be configuredto receive and combust the mixed supply of the oxidizing gas and thefuel to produce a second set of at least two flames 229′ at the secondset of at least two flame ports 226′. The second set of at least twoflames 229′ can be impinged upon the second forging surface 218 of theforging die 210 through the second set of at least two flame ports 226′to heat the second forging surface 218. In the present disclosure, theterms “impinge” or “impinged”, with reference to the various flames, canmean the flames actually contact a forging die surface or can mean thatthe flames do not actually contact a forging die surface but arepositioned proximately close to the forging die surface to suitablyconvey heat to the forging die surface.

In one non-limiting embodiment, the first set of at least two flameports 226 can comprise a plurality of uniformly, or substantiallyuniformly, spaced flame ports 226. Also, the second set of at least twoflame ports 226′ can comprise a plurality of uniformly, or substantiallyuniformly, spaced flame ports 226′. The uniform, or substantiallyuniform, spacing of the flame ports 226 and 226′ can better promoteuniform, or substantially uniform, preheating of the first and secondforging surfaces 216 and 218 of the forging die 210. The uniform, orsubstantially uniform, spacing of the various flame ports optionally canbe a feature of all non-limiting embodiments of forging die heatingapparatuses according to the present disclosure. Similar to thenon-limiting embodiments described above, a liquid, such as water, forexample, can be provided to and removed from the burner head 222 vialine 225 and/or other optional lines to cool the burner head 222 duringheating of the first forging surface 216 and the second forging surface218. In one non-limiting embodiment, a valve 233 can be positioned atone end of the line 225. The valve 225 can direct the liquid into andout of the first portion 232 and/or the second portion 234 of the burnerhead 222, for example.

In one non-limiting embodiment, referring to FIG. 8, a forging dieheating apparatus 320 for a forging die 310 is provided. The forging dieheating apparatus 320 can comprise a burner head 322 configured toreceive and combust a mixed supply of an oxidizing gas and a fuel from amixing torch (not illustrated) and/or a manifold (not illustrated)within the burner head 322. In one non-limiting embodiment, the burnerhead 322 can comprise a first side or portion 332 and a second side orportion 334. The first portion 332 can comprise at least two flame ports326, or a first plurality (i.e., three or more) of flame ports 326 and,likewise, the second portion 334 can comprise at least two flame ports326′, or a second plurality of flame ports 326′. Similar to the variousnon-limiting embodiments discussed above, the at least two flame ports326 can be used to impinge at least two flames 329 onto a first forgingsurface 316 of a top portion 312 of the forging die 310 and, similarly,the at least two flame ports 326′ can be used to impinge at least twoflames 329′ onto a second forging surface 318 of a bottom portion 314 ofthe forging die 310. In various non-limiting embodiments, the at leasttwo flame ports 326 can be uniformly, or substantially uniformly, spacedwith respect to each other. Similarly, the at least two flame ports 326′can be uniformly, or substantially uniformly, spaced with respect toeach other. As discussed above, such spacing of the various flame ports326 and 326′ can better allow the burner head 322 to uniformly, orsubstantially uniformly, preheat at least a region of the first andsecond forging surfaces 316 and 318 of the forging die 310.

Again referring to FIG. 8, in one non-limiting embodiment, a spacer 338can be provided to prevent or at least inhibit the top portion 312 ofthe forging die 310 from moving toward the bottom portion 314 of theforging die 310, at least when a portion of the forging die heatingapparatus 320 and/or the burner head 322 is positioned at leastpartially intermediate the top portion 312 and the bottom portion 314.In such an instance, the spacer 338 can be configured to prevent, or atleast reduce, the possibility that the forging die heating apparatus 320and/or the burner head 322 will be crushed between the top portion 312and the bottom portion 314 of the forging die 310 during a powerfailure, a malfunction of the forging die 310, or an inadvertentmovement of the top and/or bottom portions 312, 314, for example. In onenon-limiting embodiment, the burner head 322 can be attached to orintegrally formed with a beam 335, which beam 335 can be engaged with,attached to, or integrally formed with a portion of the spacer 338and/or a portion of a spacer 338′. While a spacer is not illustratedincorporated in each non-limiting embodiment of the present disclosure,it will be apparent that a spacer can be incorporated in or used inconjunction with the various non-limiting embodiments of forging dieheating apparatuses discussed in the present disclosure.

In one non-limiting embodiment, the spacer 338 can be comprised of anysuitable material having a strength sufficient to withstand the forcesby relative movement of the top portion 312 toward the bottom portion314 of the forging die 310. These materials can comprise, steel or caststeel, for example. In various non-limiting embodiments, more than onespacer 338 can be provided, for example. In such an embodiment, a firstspacer 338 can be provided on a first side of the burner head 322 and asecond spacer 338′ can be provided on a second side of the burner head322. In certain other non-limiting embodiments, a plurality of spacerscan at least partially surround the burner head 322 to suitably protectthe burner head 322 from being crushed and/or damaged by the relativemovement of the top and bottom portions 312 and 314 of the forging die310 toward one another. In one non-limiting embodiment, the forging dieheating apparatus 320 can comprise the spacer and/or the spacer can beintegrally formed with, attached to, separate from, and/or operablyengaged with the forging die heating apparatus 320 and/or the burnerhead 322, for example. In one non-limiting embodiment, the forging dieheating apparatus 320 can also comprise a manual or automated actuationarm 339 configured to be used to move at least the burner head 322 intoand out of a position intermediate the top portion 312 and the bottomportion 314 of the forging die 310.

In one non-limiting embodiment, referring to FIGS. 8 and 9, the forgingdie heating apparatus 320 can be configured for use with forging dies310 and 310′ having various configurations. As illustrated in FIG. 8,the forging die heating apparatus 320 can be configured for use with aflat forging die 310. In other non-limiting embodiments, referring toFIG. 9, the forging die heating apparatus 320 can be configured for usewith a vee forging die 310′, for example. The vee forging die 310′ cancomprise a first V-shaped region 340 in a first forging surface 316′ anda second V-shaped region 340′ in a second forging surface 318′. In suchan embodiment, referring to FIG. 9, the flames 329 and 329′ respectivelyproduced at the flame ports 326 and 326′ can be long enough to impingeon and/or adequately convey heat to all or a region of the side walls342 and 342′ of the V-shaped regions 340 and 340′, for example. Incertain non-limiting embodiments, the flames 329 and 329′ produced bythe forging die heating apparatus 320 can be longer when adapted for usewith the vee forging die 310′ (FIG. 9) than for use with a flat forgingdie 310 (FIG. 8), for example. In such an instance, a mixing torch (notillustrated) can provide the mixed supply of the oxidizing gas and thefuel to the burner head 322 at a higher velocity, and optionally, at ahigher flow rate, when preheating the vee forging die 310′ than whenpreheating the flat forging die 310. In other non-limiting embodiments,the diameter, perimeter, and/or shape of the flame ports 326 and 326′can be suitably adjusted to produce longer flames 329 and 329′ at theflame ports 326 and 326′ when preheating the vee forging die 310′, forexample. In certain other non-limiting embodiments, which are notillustrated herein, the forging die heating apparatus 320 can beconfigured for use with any other suitable forging die configuration orforging die surface configuration or orientation. The forging dieheating apparatus 320 can also comprise a manual or automatic actuationarm 339′ configured to be used to move the at least the burner head 322into and out of a position at least partially intermediate the topportion 312′ and the bottom portion 314′ of the forging die 310′.

In one non-limiting embodiment, referring to FIG. 9, a forging die driftequipment safety-hard stop 380 can be configured to prevent or at leastinhibit the top portion 312′ of the forging die 310′ from driftingtoward the bottom portion 314′ of the forging die 310′ during a powerfailure or at other appropriate times, such as when the forging die 310′is being heated by the burner head 322, for example. The forging diedrift equipment safety-hard stop 380 can comprise an arm 382 attached ata first end portion to a wall 384 or other rigid support structure andattached at a second end portion to the spacer 338′. The first endportion of the arm 382 can be attached to the wall via a bolt 386, forexample, or by other suitable attachment members or methods, such aswelding, for example. In other non-limiting embodiments, the arm 382 canbe integrally formed with the wall 384 and/or the spacer 338′, forexample. In any event, the arm 382 can comprise a swivel member 388positioned intermediate the first end portion and the second end portionof the arm 382. The swivel member 388 can be used to swivel the spacer338′, about axis 381, between a first position, where it is positionedat least partially intermediate the top portion 312′ and the bottomportion 314′ of the forging die 310′ (as illustrated), and a secondposition, where the spacer 338′ is not positioned intermediate the topportion 312′ and the bottom portion 314′ of the forging die 310′. Theswivel member 388 can be manually actuated or can be automated. Theforging die drift equipment safety-hard stop 380 can prevent or at leastinhibit the forging die 310′ from crushing the burner head 322 during apower failure or at other suitable times, such as when the forging die310′ is being heated by the burner head 322. Although the forging diedrift equipment safety-hard stop 380 is illustrated as being used withthe forging die 310′, it will be understood that the forging die driftequipment safety-hard stop 380 can be used with any of the variousforging die disclosed herein or can be used with other suitable forgingdies.

In various non-limiting embodiments, referring to FIGS. 10 and 11, aforging die heating apparatus 420 for a forging die 410 can comprise aburner head 422 comprising a first set of at least two burner portions432 and 432′ and a second set of at least two burner portions 434 and434′. In other non-limiting embodiments, a burner head can comprise morethan four burner portions, for example. The various burner portions canbe supported by a cross member 435, which can optionally be engagedwith, attached to, or integrally formed with spacers 438 and 438′. Theburner portion 432 can be movable with respect to the burner portion432′ and/or with respect to a forging surface 416 of a top portion 412of the forging die 410 to conform at least a portion of the burner head422 to an orientation of the forging surface 416 of the forging die 410.By conforming the portion of the burner head 422 to an orientation ofthe forging surface 416, flame ports 426 located on the burner head 422can be conformed to the forging surface 416, for example, such thatflames 429 can be impinged upon the forging surface 416. The burnerportion 432 can be movable manually by an operator or through the use ofan actuator, such as a pneumatic actuator, for example. The other burnerportions 432′, 434, and 434′ can also be movable in a similar fashion.In such an embodiment, the burner portions 432, 432′, 434, and 434′ ofthe burner head 422 can be moved to conform an orientation of aplurality of flame ports 426 or 426′ on the burner portions 432, 432′,434, and 434′ to an orientation of a portion of the forging surfaces 416or 418 of the forging die 410. In various non-limiting embodiments, theburner portions 432, 432′, 434, and 434′ can be moved to conform anorientation of the plurality of flame ports 426 and 426′ on the burnerportions 432, 432′, 434, and 434′ to an orientation of a portion of theforging surfaces 416 and 418 of the flat forging die 410 (see FIG. 10)or the vee forging die 410′ (see FIG. 11), for example.

Similar to that discussed above, referring to FIG. 11, the vee forgingdie 410′ can comprise a top portion 412′ comprising a first forgingsurface 416′ and a bottom portion 414′ comprising a second forgingsurface 418′. The first forging surface 416′ and the second forgingsurface 418′ can comprise V-shaped regions 440 and 440′, respectively.The V-shaped region 440 can comprise a side wall 442 and, likewise, theV-shaped region 440′ can comprise a side wall 442′. By allowing formovement of the burner portions 432, 432′, 434, and 434′, the forgingdie heating apparatus 420 can be configured in an orientation touniformly, or substantially uniformly, preheat the forging surfaces 416and 418 and/or the sidewalls 442 and 442′ of the V-shaped portions 440and 440′. The forging die heating apparatus 420 can also comprise or beused with a spacer 438 and/or a spacer 438′. The functionality of thevarious spacers is described herein with respect to other non-limitingembodiments and will not be repeated here for the sake of brevity.Referring to FIGS. 10 and 11, the forging die heating apparatus 420 canalso comprise a manual or automated actuation arm 439 or 439′ configuredto be used to move at least the burner head 422 into and out of aposition intermediate the top portion 412 or 412′ and the bottom portion414 or 414′ of the forging die 410 or 410.

In certain non-limiting embodiments, referring to FIG. 10, a forging diedrift equipment safety-hard stop 480 can be configured to prevent, or atleast inhibit, the top portion 412 of the forging die 410 from driftingtoward the bottom portion 414 of the forging die 410 during a powerfailure or at other appropriate times, such as during heating of theforging die 410, for example. Although, the forging die drift equipmentsafety-hard stop 480 is illustrated in conjunction with the spacers 438and 438′, it will be recognized that either the spacers 438 and 438′ orthe forging die drift equipment safety-hard stop 480 can be usedindependently to perform the same or a similar function (i.e.,preventing, or at least inhibiting, the burner head 422 from beingcrushed between the top portion 412 and the bottom portion 414 of theforging die 410). In one non-limiting embodiment, the top portion 412 ofthe forging die 410 can be attached to or integrally formed with abolster 490 (only a portion of the bolster is illustrated). The bolster490 can extend from a side wall 492 of the top portion 412 of theforging die 410 and can include a surface 494 configured to be engagedwith a portion of a removable spacer 496. The forging die driftequipment safety-hard stop 480 can comprise an arm 482 attached to awall 484 or other rigid support structure at a first end portion andconfigured to be removably engaged with the removable spacer 496 at asecond end portion. The first end portion of the arm 482 can be attachedto the wall 484 using a bolt 498, for example, or any other suitableattachment members or methods, such as welding, for example. In onenon-limiting embodiment, the arm 482 can be integrally formed with thewall 484, for example. In any event, the removable spacer 496 can bemanually or automatically positioned intermediate the surface 494 of thebolster 490 and the second end portion of the arm 482. The removablespacer 496 can be positioned at least partially intermediate the surface494 and the second end portion of the arm 482 during a power failureand/or during heating of the forging die 410 to prevent, or at leastinhibit, the forging die 410 from crushing the burner head 422. Althoughthe forging die drift equipment safety-hard stop 380 is illustrated asbeing used with the forging die 410, it will be understood that theforging die drift equipment safety-hard stop 480 can be used with anyforging die disclosed herein or with other suitable forging dies.

In one non-limiting embodiment, referring to FIG. 12, a forging dieheating apparatus 520 for a forging die can comprise a burner head 522comprising a first portion 532 and a second portion 534. The firstportion 532 can be connected to the second portion 534 by a movablemember 538, such as a pivot or a hinge, for example, to allow relativemovement between the first and second portions 532 and 534. The movablemember 538 can be individually attached to the first portion 532 and thesecond portion 534 by a bracket 539, for example, or through the use ofany other suitable attachment member. In other non-limiting embodiments,the movable member 538 can be integrally formed with or fixedly attachedto the first portion 532 and/or the second portion 534 of the burnerhead 522. In any event, the first portion 532 can be moved relative tothe second portion 534 and/or relative to a forging surface of a forgingdie (not illustrated) about the movable member 538 and/or the secondportion 534 can be moved relative to the first portion 532 and/orrelative to the forging surface of the forging die. Such permittedmovement of the burner head 522 can allow flame ports 526 and 526′ ofthe burner head 522 to be conformed to an orientation or configurationof a portion of a forging surface of a forging die such that uniform, orsubstantially uniform, preheating of the portion of the forging surfacecan be achieved when flames 529 and 529′ are provided at the flame ports526 and 526′.

In one non-limiting embodiment, the forging die heating apparatus 520can comprise a member 554 supporting the first portion 532 and a member554′ supporting the second portion 534. The member 554 can be movablyattached to the first portion 532 via a pivotable element 560 and,likewise, the member 554′ can be movably attached to the second portion534 via a pivotable element 560′. Such attachment can allow the firstportion 532 to move relative to the member 554 and/or the movable member538, and can allow the second portion 534 to move relative to the member554′ and/or the movable member 538. Such movement can be manuallyaccomplished by an operator of the forging die heating apparatus 520,for example. In one non-limiting embodiment, the forging die heatingapparatus 520 can be locked into place after being conformed to forgingsurfaces of the forging die using any suitable locking mechanisms knownto those of ordinary skill in the art.

In one non-limiting embodiment, referring to FIG. 13, a forging dieheating apparatus 520′ can comprise an actuator 550 configured to beoperably engaged with the first portion 532 of the burner head 522 tomove the first portion 532 about the movable member 538 and/or about thepivotable element 560. In the illustrated exemplary embodiment of FIG.13, a first end 552 of the actuator 550 can be attached to or formedwith the member 554 supporting the first portion 532 of the burner head522′, and a second end 556 of the actuator 550 can be attached to orformed with the first portion 532 of the burner head 522′ via a bracketand pivot member 558. The actuator 550 can extend at any suitable anglewith respect to a side wall 553 of the member 554. The member 554 canalso be movably attached to the first portion 532 of the burner head522′ via the pivotable element 560. The bracket and pivot member 558 andthe pivotable element 560 can allow the first portion 532 to moverelative to the movable member 538, the member 554, and/or the secondportion 534 of the burner head 522′. Of course, an actuator could alsobe provided which can move both the first portion 532 and the secondportion 534 of the burner head 522′.

In one non-limiting embodiment, still referring to FIG. 13, an optionalsecond actuator 550′ can be provided to move the second portion 534 ofthe burner head 522′ in a manner similar to the first portion 532 of theburner head 522′. More particularly, a first end 552′ of the actuator550′ can be attached to a member 554′ supporting the second portion 534of the burner head 522′, and the second end 556′ of the actuator 550′can be attached to the second portion 534 of the burner head 522′ via abracket and pivot member 558′. Similar to the actuator 550 describedabove, the actuator 550′ can extend at any suitable angle with respectto a side wall 553′ of the member 554′. Also, the member 554′ can bemovably attached to the second portion 534 of the burner head 522′ via apivotable element 560′. As a result, the actuators 550 and 550′ can movethe first and second portions 532 and 534 of the burner head 522′relative to each other and/or relative to a forging surface of a forgingdie. In one non-limiting embodiment, the various movable or pivotablecomponents of the forging die heating apparatus 520′ can belubricant-free, high-temperature resistant, and designed to operate inclose proximity to the burner head 522′.

In one non-limiting embodiment, referring to FIG. 14, actuators 550 and550′ can be used in conjunction with forging die heating apparatus 520″.Forging die heating apparatus 520″ can comprise a burner head 522″comprising a first portion 532″ and a second portion 534″ that areindependent of each other (i.e., not connected by a movable member, suchas movable member 538). In various circumstances, it may be desirable tohave the first and second portions 532″ and 534″ independent from eachother to allow for a greater degree of movement of the first secondportions 532″ and 534″ about each other and/or with respect to a forgingsurface of a forging die. Stated another way, by not connecting thefirst and second portions 532″ and 534″, an operator using the forgingdie heating apparatus 520″ can configure the first and second portions532″ and 534″ of the forging die heating apparatus 520″ into anysuitable configuration and/or orientation.

In one non-limiting embodiment, referring to FIGS. 13 and 14, theactuators 550 and 550′ can be comprised of compressed air, mechanical,electrical, hydraulic, pneumatic, and/or any other suitable type ofactuators configured to be used in a high temperature environment. Inone non-limiting embodiment, the actuators 550 and 550′ can comprisecompressed air-actuated pistons 562 and 562′, respectively, which canextend and retract from housings 564 and 564′, respectively, to move thefirst portion 532 or 532″ and the second portion 534 or 534″ relative toeach other and/or relative to a forging surface of a forging die. In onenon-limiting embodiment, piston 562 can move in the directions indicatedby arrow “E” and piston 562′ can move in the directions indicated byarrow “F”, for example. In other various non-limiting embodiments, anysuitable number, configuration, or type of actuators can be providedwith or used with the forging die heating apparatuses described herein.In one non-limiting embodiment, the various actuators can be configuredto move at least a portion of the burner head at least between a firstconfiguration and a second configuration to at least partially conformthe flame ports of the burner head to the orientation of a region ofvarious forging surfaces of a forging die.

In one non-limiting embodiment, the mixed supply of oxidizing gas andfuel supplied to the various flame ports can be at least partiallycomprised of an air-aspirated fuel, for example, and/or any othersuitable oxidizing gas and/or fuel. The oxidizing gas is provided in themixed supply of the oxidizing gas and the fuel to facilitate combustionof the fuel. In one non-limiting embodiment it may be desirable toachieve faster and/or higher temperature preheating of forging surfacesof forging dies. In such an embodiment, the supply of the oxidizing gascan be predominantly or substantially oxygen, and the supply of fuel canbe any suitable fuel that can be combusted in the presence of oxygen,such as acetylene, propylene, liquefied petroleum gas (LPG), propane,natural gas, hydrogen, and MAPP gas (a stabilized mixture ofmethylacetylene and propadiene), for example. By combusting such a fuelwith an oxidizing gas predominantly or substantially comprised ofoxygen, faster and higher-temperature heating of the forging surfaces ofthe forging dies can be achieved relative to combusting the fuel usingambient air as the oxidizing gas. Given that ambient air comprises onlyabout 21 volume percent oxygen, preheating techniques using air as theoxidizing gas to facilitate combustion of the fuel can increase the timerequired for preheating and reduce the temperature of the forgingsurface achieved through preheating. Using a mixed supply comprising anoxygen-combustible fuel and an oxidizing gas comprised predominantly ofoxygen (referred to herein as an “oxy-fuel”), the various non-limitingforging die heating apparatuses and methods of the present disclosurecan relatively rapidly (for example, in 5 to 10 minutes) preheat all ofor a region of a forging surface of a forging die to temperatures in therange of 700° F. to 2000° F., for example. Such temperatures aresignificantly higher than temperatures achieved in certain conventionalforging die preheating techniques. Additionally, the use of an oxy-fuelcan significantly reduce the time required to preheat the forging diesand/or the forging surfaces of the forging dies to the requiredtemperature and can achieve a higher temperature preheat, therebyeliminating or at least minimizing the temperature differential betweena heated work piece and the forging surfaces.

In one non-limiting embodiment, the present disclosure, in part, isdirected to a method of heating a forging die or at least a region of aforging surface of a forging die. The method can comprise positioning aburner head comprising at least two flame ports in proximity to at leasta region of a forging surface of the forging die and supplying a fuel,such as an oxy-fuel, for example, and an oxidizing gas to the at leasttwo flame ports. The oxy-fuel can then be combusted at the at least twoflame ports to produce a flame, such as an oxy-fuel flame, for example,at each of the at least two flame ports. The at least two flames canthen be impinged onto at least the region of the forging surface of theforging die to uniformly, or substantially uniformly, heat the region ofthe forging surface of the forging die.

In one non-limiting embodiment, the method can comprise using a burnerhead comprising a first portion comprising a first set of flame portscomprising at least two flame ports and a second portion comprising asecond set of flame ports comprising at least two flame ports. Themethod can further comprise moving at least one of the first portion andthe second portion relative to a forging surface of a forging die. Assuch, an orientation of at least the first set of flame ports can be atleast partially conformed to an orientation of a region of the forgingsurface of the forging die. In other non-limiting embodiments, themethod can comprise using a burner head comprising a first portioncomprising a first set of flame ports comprising at least two flameports and a second portion comprising a second set of flame portscomprising at least two flame ports. The method can further comprisemoving the burner head from a first configuration to a secondconfiguration relative to the forging surface of the forging die usingan actuator operably engaged with the burner head. As such, anorientation of at least the first set of flame ports can be at leastpartially conformed to an orientation of a region of the forging surfaceof the forging die. The method can further comprise using a forging diecomprising a first forging surface and a second forging surface, andpositioning the burner head intermediate the first forging surface andthe second forging surface during the heating of the region of theforging surface. In one non-limiting embodiment, the burner head can bepositioned a distance of 0.5 inches to 8 inches, a distance of 1 inch to6 inches, or a distance of 1.5 inches to 3 inches, for example, from theregion of the forging surface of the forging die prior to impinging theat least two flames onto the region of the forging surface. In variousnon-limiting embodiments, the burner head can be positioned, parallel,or substantially parallel, to the region of the forging surface of theforging die during flame impingement. In various other non-limitingembodiments, the burner head can comprise a surface having an area whichcorresponds to and/or is substantially the same as an area of theforging surface.

In one non-limiting embodiment, the method can comprise monitoring thetemperature of at least a portion of a forging die and intermittentlyimpinging, based on the monitoring, at least two flames, such asoxy-fuel flames, for example, onto a forging surface of the forging dieto adjust the temperature of at least the portion of the forging surfaceand/or the forging die to at least a minimum desired temperature. Insuch non-limiting embodiments, thermocouples, thermopiles, fiber opticinfra-red sensors, heat flux sensors, and/or other devices suitable forconverting thermal energy into electrical energy (together referred toherein as “temperature sensors”) can be positioned within the forgingdie, around the perimeter of the forging die, on forging surfaces of theforging die, and/or within the flame ports of the burner head, forexample, such that an operator of a forging die heating apparatus canreceive feedback as to the temperature of the forging surfaces of theforging die during a forging die preheating process. In one non-limitingembodiment, the temperature sensors can be rated for sensingtemperatures in the range of 800-3000° Fahrenheit, for example. Suitabletemperature sensors such as thermocouples, for example, are readilycommercially available and, therefore, are not discussed further herein.

One exemplary non-limiting embodiment of the positioning of thetemperature sensors that may be used in certain embodiments according tothe present disclosure is illustrated in FIG. 15. As illustrated, one ormore temperature sensors 670, which are indicated by the numbers 1-n,where n is a suitable integer, can be positioned on and/or within a topportion 612 of a forging die, for example. The temperature sensors 670can be positioned within the top portion 612 by drilling holes in thetop portion 612 and then inserting the temperature sensors 670 into theholes, for example. Of course, similar temperature sensors, or othertypes of temperature sensors, can be positioned on and/or within abottom portion (not illustrated) or other portion of the forging die.The positions of the temperature sensors 1-n can allow accuratemonitoring of the temperature, or temperature range, whether absolute,differential, or gradient, of the top portion 612 of the forging dieand/or the forging surface 616 of the top portion 612. The temperaturesensors 1-n can also be used to validate a forging die heating rate whenusing a particular fuel, such as oxy-fuel, for example. Those of skillin the art will recognize that the temperature sensors 670 can bepositioned within the top portion 612 (and/or the bottom portion),and/or on or near the forging surface 616 of the top portion 612 (and/orthe bottom portion), in any suitable position, arrangement, and/ororientation.

In one non-limiting embodiment, referring to FIGS. 2, 15, and 16, aclosed-loop on/off flame impingement system can be provided fortemperature control of at least a portion of the forging die and/or theforging surface 616 of the forging die. Electrical energy (e.g., voltageor current) output signals from the temperature sensors 670, indicativeof the temperature T2 of a portion of the forging die and/or the forgingsurface 616, can be received by a logic controller 672, such as aprogrammable logic controller (PLC) or other suitable logic controller,for example. The logic controller 672 converts the electrical energyreceived from the temperature sensors 670, which is proportional totemperature T2, into an electrical signal suitable for feedback control.For example, in one non-limiting embodiment, the logic controller 672converts the electrical energy from the temperature sensors 670 into aseries of pulses or other signals suitable for controlling the operationof a normally-closed solenoid valve 674, or other suitable valve, tocontrol the opening and closing of the solenoid valve 674. In variousnon-limiting embodiments, the solenoid valve 674 can be positioned inthe conduit 31 (or other conduit), such that it can be locatedintermediate a mixed supply of an oxidizing gas and a fuel in the mixingtorch 24 and the burner head 22 (see e.g., FIG. 2). In othernon-limiting embodiments, a solenoid valve can be positioned in each ofthe lines or conduits (not illustrated) supplying the oxidizing gasand/or the fuel to the mixing torch 24, for example. In any event, thesolenoid valve 674 can be opened or closed based on the series of pulsesor signals outputted by the logic controller 672. In one non-limitingembodiment, the logic controller 672 may be configured such that whenthe temperature of the forging surface 616 and/or portions of theforging die are within or above a predetermined required temperature orrequired temperature range, the logic controller 672 maintains thesolenoid valve 674 in a closed position to prevent the flow of the mixedsupply of the oxidizing gas and the fuel to the burner head 22 forcombustion. Still in one non-limiting embodiment, when the temperatureof the forging surface 616 and/or portions of the forging die are belowthe predetermined required temperature or the required temperaturerange, the logic controller 672 can output pulses or signals that causethe solenoid valve 674 to open and thus enable the flow of the mixedsupply of the oxidizing gas and the fuel to the burner head 22 forcombustion. In one non-limiting embodiment, aproportional-integral-derivative (“PID”) controller (not illustrated)can be used in the closed loop on/off flame impingement system in lieuof the local controller 672, as is known to those of ordinary skill inthe art. The PID controller can be used to control the opening and/orclosing of the solenoid valve 674 to at least intermittently heat theforging surface 616 and/or other portions of the forging die to thepredetermined required temperature or the predetermined requiredtemperature range. In various non-limiting embodiments, and, of course,depending on the material composition of the forging dies, thetemperature can be maintained between 700 and 2000 degrees Fahrenheit,when using an oxy-fuel, for example.

In one non-limiting embodiment, and referring to FIG. 16, a fiber opticinfra-red thermometer 676, sensor, or other suitable temperature sensingdevice (together referred to herein as a “temperature sensor”) can bepositioned within or proximate to the flames extending from a flame portof the burner head 22 to measure the temperature T1 of the burner head22, the flames, and/or the temperature of the forging surface 616. Inother non-limiting embodiments, more than one temperature sensor 676 canbe provided in one or more than one flame extending from or positionedwithin the flame ports of the burner head 22. Suitable temperaturesensors are commercially available from Mikron, Ameteck, or OmegaInstruments, for example. Such temperature sensors can provide anelectrical signal proportional to thermal energy of the flame or theforging surface, for example. In one non-limiting embodiment, thetemperature sensor 676 can be included in the closed-loop on/off flameimpingement system described above to provide flame temperature and/orforging surface temperature T1 feedback to an operator. In onenon-limiting embodiment, the flame temperature and/or forging surfacetemperature T1 feedback can be displayed on a display 678, such as aliquid crystal display, for example. Those skilled in the art willappreciate that the electrical energy output of the temperature sensorsmay be read directly by circuitry provided within the display 678.Although the closed-loop on/off flame impingement system is describedwith respect to one non-limiting embodiment of the disclosure, it willbe understood that it can be used with each non-limiting embodiment orother various embodiments.

In one non-limiting embodiment, referring to FIG. 17, one or more fiberoptic infra-red thermometers, sensors, or other temperature sensingdevices (together referred to as “temperature sensors 701”) can bepositioned within flame ports 726 of a burner head 722 of a forging dieheating apparatus. The burner head 722 can be similar to the variousburner heads described herein. In one non-limiting embodiment, theburner head 722 can be positioned proximate to the forging surface 716of the top portion 712 of a forging die such that flames 729 emittedfrom the flame ports 722 can be impinged upon the forging surface 716.The temperature sensors 701 can sense the thermal energy of the forgingsurface 716 and convert the thermal energy into electrical energy.

Optional temperature sensors 770, labeled 1-3, can be positioned onand/or within the top portion 712 of the forging die and proximate tothe forging surface 716 to measure the temperature of regions of the topportion 712. Of course, similar temperature sensors, or other types oftemperature sensors, can be positioned on and/or within a bottom portion(not illustrated) or other portion of the forging die. The temperaturesensors 770 can be the same as or similar to the temperature sensors 670described above and, therefore, will not be described in detail withrespect to FIG. 17 for the sake of brevity.

In one non-limiting embodiment, referring to FIG. 18, a differentclosed-loop on/off flame impingement system can be provided fortemperature control of at least a region of the forging die and/or theforging surface 716 of the forging die. In one non-limiting embodiment,the temperature sensors 701 can read the thermal energy of the forgingsurface 716 of the forging die 802 and output electrical energy (e.g.,voltage or current) indicative of the temperature of the forging surface716, to a logic controller 804. The logic controller 804 can be aprogrammable logic controller (PLC) or other suitable logic controller,for example, and can be associated with a display 806, such as a liquidcrystal display, for example, to provide feedback of the temperature ofthe forging surface 716 to an operator of a forging die heatingapparatus. The display 806 can include the appropriate circuitry tointerpret the electrical energy supplied by the temperature sensors 701and display an output indicative of the temperature of the forgingsurface. In one non-limiting embodiment, the logic controller 804 canconvert the electrical energy received from the temperature sensors 701into a format for outputting to the display 806. The logic controller804 can also interpret the electrical energy received from thetemperature sensors 701 and convert the electrical energy into a seriesof pulses or other signals suitable for controlling (i.e., openingand/or closing) one or more solenoid valves 808, or other suitablevalves, to control the amount of oxidizing gas and fuel that is fed intoa mixing torch 824 at a particular time. The solenoid valves 808 can bepositioned on lines between a supply of the oxidizing gas 810 and themixing torch 824 and a supply of the fuel 812 and the mixing torch 824.The amount of the oxidizing gas and the fuel fed into the mixing torch824 can be proportional to the temperature of the forging surface 716.Stated another way, the amount of the oxidizing gas and the fuel fedinto the mixing torch 824 can be based on the differential between thetemperature of the forging surface 716 and a predetermined requiredtemperature, or a predetermined required temperature range, of theforging surface 716. As such, if the temperature of the forging surface716 is below the predetermined required temperature, or thepredetermined required temperature range, the oxidized gas and the fuelcan be fed into the mixing torch 824 as the pulses, or other signals,from the logic controller 804 will instruct the solenoid valve to open,partially open, or remain open. If the temperature of the forgingsurface 716 is above the predetermined required temperature, or thepredetermined required temperature range, the oxidized gas and the fuelmay not be fed into the mixing torch 824 as the pulses or signals fromthe logic controller 804 will instruct the solenoid valve 808 to close,partially close, or remain closed. Upon consideration of the presentdisclosure, those of skill in the art will recognize that variousamounts of the oxidizing gas and the fuel can be intermittently fed intothe mixing torch 824 as the solenoid valves 808 open and/or close afterreceiving various pulses, or other signals, from the logic controller804 to maintain the temperature of the forging surface 716 at thepredetermined required temperature, or the predetermined requiredtemperature range.

In another non-limiting embodiment, a proportional-integral-derivative(“PID”) controller (not illustrated), as is known to those of ordinaryskill in the art, can be used in the closed loop on/off flameimpingement system in lieu of the logic controller 804. The PIDcontroller can be used to control the opening and/or closing of thesolenoid valves 808 in a similar fashion as the logic controller 804. Invarious non-limiting embodiments, and, of course, depending on thematerial composition of the forging dies and/or the burner head 822, thetemperature can be maintained between 700 and 2000 degrees Fahrenheit,when using an oxy-fuel, for example.

In one non-limiting embodiment, the oxidizing gas and the fuel can befed into a flow regulator 814. The flow regulator 814 may include flowrate gauges 816 and pressure gauges 818 for monitoring the flow rate andpressure, respectively, of the oxidizing gas and the fuel through theflow regulator 814. The flow regulator 814 may also include the solenoidvalves 808, which are configured to open and close based on pulses, orsignals, received from the logic controller 804. If the solenoid valves808 are open, or partially open, the oxidizing gas and the fuel can befed through the flow regulator 814 and, if the solenoid valves 808 areclosed, the oxidizing gas and the fuel will not be allowed to flowthrough the flow regulator 814. As such, the logic controller 804 cansend pulses, or signals, to the solenoid valves 808 to open and/or closethe solenoid valves 808 and intermittently permit the flow of theoxidizing gas and the fuel through the flow regulator 814. Of course,the flow rate of the oxidizing gas and the flow rate of the fuel canhave any suitable ratio suitable for adequate combustion.

In one non-limiting embodiment, still referring to FIG. 18, once theoxidizing gas and the fuel exits the flow regulator 814, these can enterthe mixing torch 824, such that the oxidizing gas can be mixed with thefuel and then fed into burner head 822, or a manifold within the burnerhead 822, for combustion. When the oxidizing gas and fuel mixture is fedinto the burner head 822, or the manifold within the burner head 822, apilot igniter 820 can be activated, via pulses or signals received fromthe logic controller 804, to ignite the mixed supply of the oxidizinggas the fuel.

As discussed above, the burner head 822 can be cooled using a liquid,vapor, and/or a gas, for example. In one non-limiting embodiment, water826 from a facility can be fed into the burner head 822, run through theburner head 822 to cool the burner head 822 by absorbing heat from themetal portions of the burner head 822, and then flowed out of the burnerhead 822 to a water recycle or waste pit 828 or other suitable wastearea. A temperature sensor 830 can be provided in the waste line betweenthe burner head 822 and the water recycle or waste pit 828 to track thetemperature of the waste water. The temperature of the waste water may,in some instances, indicate to an operator that the burner head 822 isoverheating. In one non-limiting embodiment, the temperature of thewaste water may normally be above the ambient temperature and/or withinthe range of 60 degrees Fahrenheit to 90 degrees Fahrenheit, forexample, depending on the flow rate of the waste water. If thetemperature of the waste water reaches about 110 degrees Fahrenheit, forexample, this may indicate that the burner head 822 is overheating andshould be shut down or that more cooling water should be provided to theburner head 822. In other non-limiting embodiments, if the temperaturesensor 830 senses a temperature of the waste water at approximately 110degrees Fahrenheit, for example, the burner head 822 may beautomatically shut down or more cooling water may be automaticallyprovided to the burner head 822. Those of skill in the art willrecognize that the temperature sensor 830 can read thermal energy of thewaste water and convert that thermal energy into electrical energy. Theelectrical energy can then be provided to the display 806. As referencedabove, the display 806 may include the appropriate circuitry tointerpret the electrical energy and provide a readout indicative of thetemperature of the waste water.

In one non-limiting embodiment, referring to FIG. 19, a system formonitoring the temperature of a forging surface 916 of at least aportion 910 of a forging die is provided. In such a non-limitingembodiment, one or more infra-red thermometers (hereafter “IRthermometers”) 914 may be positioned a distance away from a face 918 ofthe burner head 922 that is not facing the forging surface 916. The oneor more IR thermometers 914 may be positioned at a distance of 1 to 12inches and alternatively 2 to 4 inches, for example, from the face 918of the burner head 922. One or more apertures 920 may be defined throughthe burner head 922, such that the IR thermometers 914 may emit a beam919 to sense various properties of the forging surface 916 through theburner head 922. In one non-limiting embodiment, the apertures 920 maybe ¼″ holes that are drilled through the burner head 922 using asuitable drill bit, for example. In other non-limiting embodiments, theapertures 920 may have any other suitable sizes. In any event, theapertures 920 may be sufficiently sized to allow IR radiation from theheated forging surface 916 to be sensed from the non-flame side of theburner head 922 for temperature monitoring and temperature control ofthe forging surface 916. The one or more apertures 920 will not disruptthe flow of water or the mixture of the oxidizing gas and the fuelflowing through the burner head 922, as the apertures 920 may be placedbetween adjacent flame ports, for example. The IR thermometers 914 maybe electrically connected to a logic controller, such as logiccontroller 804, for example. In one non-limiting embodiment, the IRthermometer 914 may be used in place of the temperature sensor 701 ofFIG. 18, for example.

In one non-limiting embodiment, the one or more IR thermometers 914 mayneed to be jacketed or shielded to protect heat sensitive areas, such asthe electronics and the optics (i.e., lens), for example, of the one ormore IR thermometers 914 from the high temperature air surrounding theburner head 922 and/or from the heat being radiated by the burner head922 and/or the forging surface 916. In certain non-limiting embodiments,due to potential thermal degradation of especially the electronics andoptics of the one or more IR thermometers 914 caused by exposure to hotgases flowing through the one or more apertures 920, a small blower 921,such as a 75 cubic feet per hour blower, for example, may be used todeflect the hot gases from the one or more IR thermometers 914. Theblower 921 may be positioned such that it provides air flow in adirection along or substantially along the face 918, for example, asindicated by the arrows of FIG. 19. Temperature monitoring andtemperature control of the forging surface 916 is possible through theuse of IR thermometer sensing through flames 929 or by IR thermometersensing during burner-off cycles between timed flame pulse cycles.Sensing the temperature of the forging surface 916 through the flames929 may enable real time On-Off set point control, while sensing throughflame pulse dwells may provide a more rudimentary On-Off set pointcontrol with longer heating cycles than the through the flame sensingtechnique.

In one non-limiting embodiment, as discussed above, a forging die driftequipment safety-hard stop or spacer can be used to prevent, inhibit, orat least minimize a top portion of a forging die from drifting or beingforced downwards into a portion of the forging die heating apparatus andcrushing or damaging the portion of the forging die heating apparatusbetween the top portion and a bottom portion of the forging die during apower outage at a facility. The forging die drift hard-stop or spacerand the forging die heating apparatus can be attached to and/or operablyengaged with an automation arm, such as a compressed air automation arm,for example, that can be controlled by an operator using a simple panelof switches, software switches, and/or any other suitable device. The“On” position of the switches can set the forging die in “preheat mode”by bringing the top and bottom portions of the forging die into apreheating, partially closed, or substantially closed position. Theforging die heating apparatus and the forging die drift hard-stop orspacer can then be moved into a position at least partially intermediatethe top and bottom portions of the forging die and flames in flame portsof a burner head can be ignited using a spark plug, a pilot igniter, apilot lamp igniter, and/or any other suitable igniting device. Theforging die heating apparatus can then be used to preheat the forgingdie, or regions thereof, and maintain the forging die, or regionsthereof, at a predetermined required or desirable temperature or withina predetermined required or desirable temperature range. The “Off”position of the switches can shut off and/or extinguish the flames inthe flame ports of the burner head (by eliminating a supply of anoxidizing gas and a supply of a fuel from being provided to the flameports, for example) and retract the forging die heating apparatus fromthe position at least partially intermediate the top and bottom portionsof the forging die using the automation arm into a position where theforging die heating apparatus is clear of the forging die. The forgingdie can then be set into the normal “forging” mode. As is apparent tothose of ordinary skill in the art, the forging die heating apparatuscan also be positioned and removed from a position intermediate the topand bottom portions of the forging die manually, or with other types ofautomation, for example.

In one non-limiting embodiment, referring to FIG. 20, a forging dieapparatus 1000 is illustrated. The forging die apparatus 1000 comprisesa forging die 1010 including a top portion 1012 and a bottom portion1014. Each of the top portion 1012 and the bottom portion 1014 include aforging surface 1016 configured to be used to forge a work piece (notillustrated). In one non-limiting embodiment, the top portion 1012 maybe attached to or formed with a bolster 1024. The bolster 1024 may beattached to a cross head 1025. The top portion 1012, the bolster 1024,and the cross head 1025 of the forging die 1010 are movable with respectto the fixed bottom portion 1014 of the forging die 1010 such that awork piece can be forged intermediate the movable top portion 1012 andthe fixed bottom portion 1014. The forging die apparatus 1000 may alsocomprise a forging die drift hard-stop system 1018. In one non-limitingembodiment, the forging die drift hard-stop system 1018 can beconfigured to prevent, or at least inhibit, the top portion 1012 of theforging die 1010 from drifting toward the bottom portion 1014 of theforging die 1010 at an inappropriate time, such as when the forgingsurfaces 1016 are being preheated, for example.

In one non-limiting embodiment, the forging die drift hard-stop system1018 may comprise a spacer 1026 attached to a first end of an arm 1028.A second end of the arm may be pivotably attached to a portion of theforging die apparatus 1000, such that the arm 1028 may pivot withrespect to the forging die apparatus 1000 to allow movement of thespacer 1026 relative to the forging die apparatus 1000. A lever 1030 maybe fixedly or pivotably attached to the arm 1028 at a locationintermediate the first end and the second end of the arm 1028. The lever1030 may comprise a gripping handle 1031 on a first end and anengagement member 1033 on a second end. The lever 1030 and/or thegripping handle 1031 may be used by an operator of the forging dieapparatus 1000 to move the spacer 1026 from a first, disengaged position(illustrated in dashed lines) into a second, engaged position(illustrated in solid lines), and then, at an appropriate time, to movethe spacer 1026 from the second, engaged position back into the first,disengaged position. When the spacer 1026 is in the first, disengagedposition, the engagement portion 1033 of the lever 1030 can contact aplate, a bracket, or a solid portion 1032 of the forging die apparatus1000 to hold the spacer 1026 in the first, disengaged position where thespacer 1026 will not prevent the top portion 1012 of the forging die1010 from moving towards the bottom portion 1014 of the forging die1010. In other various non-limiting embodiments, an actuator (notillustrated) can be operatively engaged with the arm 1028, the lever1030, and/or the spacer 1026 to, upon activation, accomplish movement ofthe spacer 1026 between the first, disengaged position and the second,engaged position.

In one non-limiting embodiment, the solid portion 1032 may include anend 1036 configured to receive a portion of the spacer 1026, when thespacer 1026 is in the second, engaged position. Upon movement of thespacer 1026 into the second, engaged position, the spacer 1026 may be atleast partially positioned intermediate the solid portion 1032 and aportion of the cross head 1025 to prevent, or at least inhibit, the topportion 1012 of the forging die 1010 from drifting and/or moving towardthe bottom portion 1014 of the forging die 1010 at an inappropriatetime. The spacer 1026 may be comprised of a material sufficient towithstand the weight and/or force of the bolster 1024, the cross head1025, and the top portion 1012 of the forging die 1010. In onenon-limiting embodiment, although not illustrated, a forging die drifthard-stop system may be provided on more than one side of the forgingdie apparatus 1000 to maintain a balance of the weight of the cross head1025, the bolster 1024, and/or the top portion 1012 of the forging die1010. In yet another non-limiting embodiment, a winch, such as anelectrical winch (not illustrated), for example, optionally mounted tothe forging die apparatus 1000, may be configured to control themovement of the spacer 1026, the arm 1028, and/or the lever 1030, forexample. The electrical winch may comprise a wire or a cable, forexample, that is extendible from the winch and retractable toward thewinch. The electrical winch may also comprise limit switches configuredto control the range of motion of the spacer 1026, the arm 1028, and/orthe lever 1030, for example. In one embodiment, the electrical winch maybe configured to extend or uncoil the wire or cable to move the spacer1026 from the first, disengaged position into the second, engagedposition. The movement of the spacer 1026 may occur owing togravitational forces acting upon the spacer 1026. The electrical winchmay also be configured to move the spacer 1026 from the second, engagedposition into the first, disengaged position by retracting or coilingthe wire or cable. In one embodiment, the wire or cable may be attachedto the electrical winch at a first end and attached to the arm 1028 at asecond end. In such an embodiment, the lever 1030 can be eliminated. Inan embodiment where the forging die drift hard-stop system 1018 ispositioned on both sides of the forging die apparatus 1000, the spacer1026, the arm 1028, and/or the lever 1030 of each forging die drifthard-stop system 1018 may be moved simultaneously from the first,disengaged position into the second, engaged position, or vice versa,using a single pair of electrical switches, thereby making the forgingdie drift hard-stop system 1018 easy to operate.

In one non-limiting embodiment, a method of preheating an open-facedforging die can comprise positioning a burner head comprising at leasttwo flame ports in a location at least partially intermediate a firstforging surface of the forging die and a second forging surface of theforging die. In such an embodiment, the burner head can be slid, swung,pivoted, and/or moved into and out of the position at least partiallyintermediate the first forging surface and the second forging surface,for example. Such sliding, swinging, pivoting, and/or movement can bemanual or automated. In one non-limiting embodiment, the forging dieheating apparatus can be attached in a transverse, perpendicular, orsubstantially perpendicular manner to a vertically, or substantiallyvertically extending support member, such as the wall 384 of FIG. 9, forexample. The support member can be positioned proximate to the forgingdie, such that the forging die heating apparatus can be swung, moved,and/or pivoted about the support member into the position at leastpartially intermediate the top portion and the bottom portion of theforging die, for example.

In one non-limiting embodiment, an orientation of a burner head can atleast partially conform to at least one of an orientation of a firstforging surface of a forging die and an orientation of a second forgingsurface of the forging die. A method for heating a forging die cancomprise supplying a fuel to at least two flame ports, combusting thefuel to produce a flame at the least two flame ports, and impinging atleast two of the flames onto at least one of the first forging surfaceand the second forging surface. The method can also comprise positioninga spacer between the first forging surface and the second forgingsurface to prevent, inhibit, or at least minimize the first forgingsurface from moving toward the second forging surface when the burnerhead is positioned at least partially intermediate the first forgingsurface and the second forging surface. As discussed above, the fuel cancomprise an oxy-fuel. The method can further comprise impinging at leasttwo oxy-fuel flames onto at least one of the first forging surface andthe second forging surface through the at least two flame ports touniformly, or substantially uniformly, preheat at least one of the firstforging surface and the second forging surface.

In one non-limiting embodiment, referring to FIG. 21, a burner assembly1100 may be used to preheat a forging die and/or one or more forgingsurfaces of the forging die. The burner assembly 1100 may comprise asupport member 1102 configured to support an arm 1104. The supportmember 1102 may comprise a mounting bracket 1106 attached to or formedwith an end 1108 thereof. The mounting bracket 1106 may be screwed,bolted, welded, and/or otherwise attached to a surface, such as ahorizontal surface, for example. In other non-limiting embodiments, themounting bracket 1106 may be eliminated and the end 1108 may be attacheddirectly to the surface by welding, for example. In another non-limitingembodiment, the end 1108 may be formed with or attached to a base havinga sufficient area such that the burner assembly 1100 may be freestanding, for example. In still other non-limiting embodiments, the end1108 and/or the mounting bracket 1106 may be attached to a surface inany suitable manner known to those of skill in the art. The arm 1104 maybe pivotably or rotatably attached to the support member 1102, such thatthe arm 1104 may be moved about a pivot point 1110 on the support member1102, for example. In one non-limiting embodiment, the pivot point 1110may be located proximate to a mid-point of the support member 1102, forexample.

Further to the above, in one non-limiting embodiment, the arm 1104 maybe moved between a stored position (not illustrated), where a burnerhead 1112 of the burner assembly 1100 may be positioned adjacent to orproximate to a portion of the support member 1102, and a deployedposition, where the burner head 1112 may be positioned most distal fromthe support member 1102. As referenced above, the arm 1104 may be movedbetween the stored position and the deployed position by pivoting thearm 1104 about the pivot point 1110. In one non-limiting embodiment, theburner head 1112 may be attached to or formed with the arm 1104proximate to an end of the arm 1104 most distal from the pivot point1110. In other non-limiting embodiments, the burner head 1112 may beattached to or formed with other suitable portions of the arm 1104.Walls of the arm 1104 may define a channel therethrough in alongitudinal direction. The channel may be used to supply a combustiblefuel, such as natural gas, for example, to the burner head 1112. Thecombustible fuel may be supplied to the burner head 1112 at about 30psi, for example. In one non-limiting embodiment, a tube (notillustrated) may be positioned within the channel such that thecombustible fuel may flow from a fuel supply, through the tube, and tothe burner head 1112.

In one non-limiting embodiment, still referring to FIG. 21, the burnerhead 1112 may be movable, rotatable, and/or pivotable relative to thearm 1104. More specifically, the burner head 1112 may be moved from aposition where a central longitudinal axis of the burner head 1112 isgenerally parallel with a central longitudinal axis of the arm 1104, toa position where the central longitudinal axis of the burner head 1112is angled approximately 90 degrees with respect to the centrallongitudinal axis of the arm 1104, for example. In other non-limitingembodiments, the central longitudinal axis of the burner head 1112 maybe angled between 0 and 120 degrees with respect to the centrallongitudinal axis of the arm 1104, for example. This movement of theburner head 1112 may be manual or automated. The burner head 1112 may bemoved relative to the arm 1104 such that it may be positionedintermediate a forging surface of a top forging die and a forgingsurface of a bottom forging die, for example. In one non-limitingembodiment, the burner head 1112 may be moved relative to the arm 1104using an actuator 1114, such as a compressed air piston-type actuator ora hydraulic piston-type actuator, for example. A first portion of theactuator 1114 may be attached to the arm 1104 and a second portion ofthe actuator 1114 may be attached to the burner head 1112, such that asa piston 1115 of the actuator 1114 is moved into and out of a housing1117 of the actuator 1114, the burner head 1112 may be moved relative tothe arm 1104. In other non-limiting embodiments, any other suitableactuator may be used to move the burner head 1112 relative to the arm1104. In one non-limiting embodiment, the burner head 1112 can move inany suitable direction relative to the arm 1104, such that the burnerhead 1112 can be suitably positioned relative to a forging surface of aforging die.

In one non-limiting embodiment, the burner head 1112 may comprise ahousing portion 1116 and a burner head portion 1118. The housing portion1116 may comprise a manifold 1120 configured to receive the combustiblefuel from the channel, or the tube within the channel, of the arm 1104.The manifold 1120 may be in fluid communication with a plurality ofconduits 1122 used to flow the combustible fuel to one or moreassemblies 1124. In one non-limiting embodiment, the manifold 1120 maybe in fluid communication with six conduits 1122 used to flow thecombustible fuel to six assemblies 1124, for example. The assemblies1124 may each comprise an orifice configured to allow a predeterminedamount of the combustible fuel to flow therethrough. The orifices mayhave a diameter in the range of about 30 mils to about 100 mils, forexample. The orifices may regulate and/or restrict the flow of thecombustible fuel through the assemblies 1124 to provide a suitableamount of the combustible fuel to the burner head portion 1118. In onenon-limiting embodiment, the assemblies 1124 may also comprise an airaspirator configured to allow ambient air to bleed or flow into theassemblies 1124. The air aspirator may at least partially surround theassemblies 1124, for example, such that the ambient air may flow orbleed into the assemblies 1124 from any suitable direction. As a resultof the air aspirator, the combustible fuel may be mixed with the ambientair (i.e., oxidizing gas) within a plurality of tubes 1126. Theplurality of tubes 1126 may be in fluid communication with at least oneburner nozzle 1128 positioned on the burner head portion 1118. In onenon-limiting embodiment, the plurality of tubes 1126 may be in fluidcommunication with three or more burner nozzles 1128 within the burnerhead portion 1118, for example. The housing portion 1116 may comprise ashell 1130 that may at least partially surround the conduits 1122, theassemblies 1124, and/or the tubes 1126 to protect the conduits 1122, theassemblies 1124, and/or the tubes 1126 from being smashed or damagedduring use of or storage of the burner head 1112 and/or to provide aheat shield for the conduits 1122, the assemblies 1124, and/or the tubes1126, for example.

Further to the above, still referring to FIG. 21, the burner headportion 1118 may comprise the one or more burner nozzles 1128. Incertain non-limiting embodiments, a first plurality of the burnernozzles 1128 may be situated on a first side 1132 of the burner headportion 1118 and second plurality of the burner nozzles 1128 may besituated on a second side 1134 of the burner head portion 1118. In onenon-limiting embodiment, nine of the burner nozzles 1128 may bepositioned on the first side 1132 of the burner head portion 1118 andnine of the burner nozzles 1128 may be positioned on the second side1134 of the burner head portion 1118. The various burner nozzles 1128may be in fluid communication with the tubes 1126 such that the burnernozzles 1128 may receive and combust the mixture of the combustible fueland the air. In one non-limiting exemplary embodiment, three burnernozzles 1128 may be in fluid communication with one tube 1126 viaopenings or orifices in the tube 1126 at a location proximate to eachburner nozzle 1128, for example. The various burner nozzles 1128 maycomprise an igniter configured to ignite the mixture of the combustiblefuel and the air, such that the burner nozzles 1128 may produce a flame.

In operation, the burner assembly 1100 may be positioned or mountedproximate to a forging die. The arm 1104 may be moved or pivoted fromthe stored position into the deployed position. The actuator 1114 maythen be activated to move the burner head 1112 from a position where thecentral longitudinal axis of the burner head 1112 is generally parallelwith the central longitudinal axis of the arm 1104 to a position wherethe burner head 1112 is at about a 90 degree angle with respect to thecentral longitudinal axis of the arm 1104. As the burner head 1112 ismoved into the about 90 degree position, it may also be moved into aposition at least partially intermediate a top forging surface and abottom forging surface of a forging die, for example. In onenon-limiting embodiment, the burner nozzles 1128 on the first side 1132of the burner head portion 1118 may be positioned between four and eightinches away from the top forging surface and, likewise, the burnernozzles 1128 on the second side 1134 of the burner head portion 1118 maybe positioned between about four and about eight inches away from thebottom forging surface. In other non-limiting embodiments, the burnernozzles 1128 on the first side 1132 and the second side 1134 may each bepositioned about six inches away from the top and bottom forgingsurfaces of the forging die, for example.

In one non-limiting embodiment, one or more of the burner nozzles 1128on the first side 1132 and/or the second side 1134 may extend adifferent distance from the first side 1132 and/or the second side 1134than other burner nozzles 1128 positioned on the first side 1132 and/orthe second side 1134 in order to heat a forging surface of a vee die oranother forging die, for example. In other non-limiting embodiments, theburner nozzles 1128 may also be situated a various angles relative tothe first side 1132 and/or the second side 1134, again such that theburner head 1112 may be configured to heat a vee die or another forgingdie, for example. In one exemplary non-limiting embodiment, three rowsof three burner nozzles 1128 per row may be provided on the first side1132 and the second side 1134 of the burner head portion 1118. A firstrow of the burner nozzles 1128 and a third row of the burner nozzles1128 may extend a first distance from the first side 1132 and/or thesecond side 1134 and a second row of the burner nozzles 1128 may extenda second distance from the first side 1132 and/or the second side 1134.The first distance may be larger than or smaller than the seconddistance such that the burner head 1112 may be configured for use withforging die surfaces having various configurations, orientations and/orshapes. In other non-limiting embodiments, the burner nozzles 1128within each row may extend a different distance from the first side 1132and/or the second side 1134 and/or may extend at different anglesrelative to the first side 1132 and/or the second side 1134, forexample. Those of skill in the art, upon consideration of the presentdisclosure, will recognize that the various burner nozzles 1128 may haveany suitable configuration or orientation for appropriately heatingvariously shaped forging surfaces or forging dies.

The burner assembly 1100 may be used to preheat or heat a forging dieand/or one or more forging surfaces of the forging die from roomtemperature to about 1000 degrees Fahrenheit in approximately 30 to 45minutes, for example. Of course, other heating rates may also beachieved by varying the amount of the combustible fuel or the airprovided to the burner head 1112 by adjusting the sizes of the orificesand/or the air aspirators of the assemblies 1124, by varying the numberof burner nozzles 1128 provided on the burner head 1112, and/or byvarying the configuration and/or orientation of the burner nozzles 1128on the first and second sides 1132 and 1134 of the burner head 1112, forexample. While the burner assembly 1100 has been described as using acombustible fuel, such as natural gas, those of skill in the art willrecognize that other suitable combustible fuels may be used with theburner assembly 1100.

It will be recognized by those of skill in the art that features orcomponents of particular non-limiting embodiments described herein canbe used in conjunction with other non-limiting embodiments describedherein and/or with other non-limiting embodiments within the scope ofthe claims.

Although the foregoing description has necessarily presented only alimited number of embodiments, those of ordinary skill in the relevantart will appreciate that various changes in the apparatuses and methodsand other details of the examples that have been described andillustrated herein may be made by those skilled in the art, and all suchmodifications will remain within the principle and scope of the presentdisclosure as expressed herein and in the appended claims. For example,although the present disclosure has necessarily only presented a limitednumber of non-limiting embodiments of forging die heating apparatuses,and also has necessarily only discussed a limited number of non-limitingforging die heating methods, it will be understood that the presentdisclosure and associated claims are not so limited. Those havingordinary skill will readily identify additional forging die heatingapparatuses and methods and may design and build and use additionalforging die heating apparatuses and methods along the lines and withinthe spirit of the necessarily limited number of embodiments discussedherein. It is understood, therefore, that the present invention is notlimited to the particular embodiments or methods disclosed orincorporated herein, but is intended to cover modifications that arewithin the principle and scope of the invention, as defined by theclaims. It will also be appreciated by those skilled in the art thatchanges could be made to the non-limiting embodiments and methodsdiscussed herein without departing from the broad inventive conceptthereof.

What is claimed is:
 1. A forging die drift hard-stop system for aforging die apparatus including a top forging portion and a bottomforging portion, wherein the top forging portion is attached to a crosshead, the forging die drift hard-stop system comprising: an armcomprising a first end and a second end, wherein the second end of thearm is pivotably attached to a portion of the forging die apparatus; anda spacer attached to the first end of the arm; wherein the arm ismovable between a first position, where the spacer is free fromengagement with a portion of the forging die apparatus and a portion ofthe cross head, and a second position, where the spacer is engaged withthe portion of the forging die apparatus and the portion of the crosshead to inhibit movement of the top forging portion toward the bottomforging portion.
 2. The forging die drift hard-stop system of claim 1,further comprising: a lever attached to the arm at a position of the armintermediate the first end and the second end, the lever comprising ahandle, and an engagement member configured to engage a solid portion ofthe forging die apparatus when the arm is in the first position tomaintain the spacer free from engagement with the portion of the forgingdie apparatus and the portion of the cross head.